Membrane electrode assembly in solid oxide fuel cells

Abstract

A membrane-electrode assembly for a solid oxide fuel cell is provided. The membrane-electrode assembly has a substantially constant-thickness electrolyte layer. The electrolyte layer distinguishes first and second electrolyte layer surfaces arranged in a three-dimensional pattern with opposite first and second planar pattern surfaces. The three-dimensional pattern has a first set of features extending inward from the first planar pattern surface. It has a second set of features extending inward from the second planar pattern surface opposite to the first planar pattern surface. A first electrode layer is adjacent and conforming to the first electrolyte layer surface. At least one mechanical support structure exists within some or all of the second set of features. A second electrode layer is adjacent and conforming to the second electrolyte layer surface and to at least one mechanical support structure. The membrane-electrode assembly is deposited on a substrate with at least one through hole.

1 . A membrane-electrode assembly for use in a solid oxide fuel cell, comprising: 
 a. an electrolyte layer having a substantially constant thickness and having opposite first and second electrolyte layer surfaces, wherein said electrolyte layer is arranged in a three-dimensional pattern having opposite first and second planar pattern surfaces, wherein said three-dimensional pattern has a first set of features extending inward from said first planar pattern surface, and a second set of features extending inward from said second planar pattern surface opposite to said first planar pattern surface of said three-dimensional pattern;    b. a first electrode layer adjacent and conforming to said first electrolyte layer surface;    c. at least one mechanical support structure within some or all of said second set of features; and    d. a second electrode layer adjacent and conforming to said second electrolyte layer surface and to said at least one mechanical support structure.    
   
   
       2 . A solid oxide fuel cell, comprising the membrane-electrode assembly of  claim 1  deposited on a substrate with at least one through hole.  
   
   
       3 . The solid oxide fuel cell as set forth in  claim 2 , wherein said second electrode layer covers some or all of the walls of said through hole.  
   
   
       4 . The solid oxide fuel cell as set forth in  claim 2 , wherein said first and second electrode layers are porous electrode layers.  
   
   
       5 . The solid oxide fuel cell as set forth in  claim 2 , wherein said substrate is a silicon wafer.  
   
   
       6 . The solid oxide fuel cell as set forth in  claim 2 , wherein said hole is a cylindrical through hole.  
   
   
       7 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrolyte layer is a dense ionic conducting oxide membrane with a thickness up to 200 nanometers.  
   
   
       8 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrolyte layer is a composition-grading membrane having a varying dopant concentration from a predominant concentration of said electrolyte to a predominant concentration of said electrode.  
   
   
       9 . The solid oxide fuel cell as set forth in  claim 8 , whereby said composition-grading membrane is fabricated using layer-by-layer deposition.  
   
   
       10 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrode layers are porous electrode layers.  
   
   
       11 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrode layers are composited with said electrolyte.  
   
   
       12 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrode layers contain a metal catalyst.  
   
   
       13 . The solid oxide fuel cell as set forth in  claim 2 , wherein said electrode layers have a thickness up to 200 nanometers.  
   
   
       14 . The solid oxide fuel cell of  claim 2 , wherein said mechanical support layers are deposited to a top side and a bottom side of said substrate.  
   
   
       15 . The solid oxide fuel cell as set forth in  claim 2 , wherein said layers and said structures are deposited using techniques comprising: DC/RF sputtering, chemical vapor deposition, pulsed laser deposition, molecular beam epitaxy, evaporation, and atomic layer deposition.  
   
   
       16 . The solid oxide fuel cell as set forth in  claim 2 , wherein said fuel cell has a total thickness from 10 nanometers to 10 micrometers.  
   
   
       17 . The thin film solid oxide fuel cell of  claim 2 , wherein boundaries between said electrolyte layer and said electrodes comprises a grain boundary formation.  
   
   
       18 . A method of making a membrane-electrode assembly, comprising: 
 a. providing a mechanical support structure having opposite first and second mechanical support structure layer surfaces, wherein said mechanical support structure is arranged in a first three-dimensional pattern, wherein said first three-dimensional pattern having a first set of features extending inward from said first mechanical support structure layer surface, and a second set of features extending inward from said second mechanical support structure layer surface opposite to said first mechanical support structure layer surface of said first three-dimensional pattern;    b. depositing an electrolyte layer of substantially constant thickness to said mechanical support structure first layer surface and conforming with said mechanical support structure first three-dimensional pattern, wherein said electrolyte layer has opposite first and second electrolyte layer surfaces, wherein said electrolyte layer is arranged in a second three-dimensional pattern, wherein said second three-dimensional pattern has a first set of electrolyte features extending inward from said first electrolyte layer surface, and a second set of electrolyte features extending inward from said second electrolyte layer surface opposite to said first layer surface of said second three-dimensional pattern;    c. depositing a first electrode layer adjacent and conforming to said first electrolyte layer surface;    d. removing said first set of mechanical support structure features and a portion of said second mechanical support structure features, wherein a remaining portion of said second mechanical support structure features and said first set of electrolyte features are exposed to form a third three-dimensional pattern made from said first electrolyte features and said mechanical support structure; and    e. depositing a second electrode layer adjacent and conformal within said second electrolyte layer surface and with said remaining second mechanical support features.    
   
   
       19 . A method of making a solid oxide fuel cell, wherein said membrane-electrode assembly of  claim 18  is deposited on a substrate with a through hole.